Industrial container having removable dunnage

ABSTRACT

An industrial container apparatus for the shipment and movement of components therein. The industrial container apparatus comprises a container body, a dunnage insert, and a releasable connector. The container body has a base and at least two walls extending from the base. The dunnage insert is configured to receive and retain the components. The releasable connector removably attaches the dunnage insert to the container body in a fixed position and a detached position. The dunnage insert is retained in the container body in the fixed position. The dunnage insert is removed from the container body in the detached position.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims benefit of U.S. Provisional Application Ser. No. 61/916,317, filed on Dec. 16, 2013, which is incorporated herein in its entirety by reference.

FIELD OF THE DISCLOSURE

The present invention relates generally to industrial shipping containers, and more particularly, to reusable shipping containers having dunnage inserts configured to receive and secure components having particular configurations so as to protect the components during shipping and transport.

BACKGROUND

In today's manufacturing industry, a wide variety of industrial shipping containers are used to transport various components to end users, such as manufacturing and assembly plants. Many of these containers receive multiple components and are designed to retain the components in such a way so as to prevent damage to the components during shipping or movement of the containers. Such containers are commonly fabricated from a rigid and lightweight material suitable for transit and movement about manufacturing facilities. The containers can be configured with open-ended or closed-ended designs and can be capable of being stacked upon one another.

In order to ensure that the components are not damaged from movement within the shipping container when being shipped to or transported within the manufacturing or assembly plant, previous designs have provided molded tray or dunnage configurations within the container wherein the dunnage is shaped specifically to hold the components in a secure position. Although such dunnage configurations may prevent damage to the components, the dunnage configurations are dedicated to a particular shape of the component, and thus, the dunnage configurations cannot be used for other differently shaped components. This can be rather costly since the shipping containers cannot be used for differently shaped components, but rather, the containers can only be used for one particularly shaped component.

Other previous designs provide dunnage inserts that may be removably inserted into the shipping container. By allowing the dunnage inserts to be removed from the shipping containers, different dunnage inserts can be exchanged for other dunnage inserts having different molded configurations for different components. Thus, the same containers can be used for different components by simply replacing the dunnage inserts. However, these dunnage inserts typically lay within the containers in a loose manner wherein the weight of the components hold the dunnage insert in the shipping container. This allows the dunnage insert to be quickly and easily removed from the container when replacing the dunnage insert with a different configured dunnage insert. The problem with such a design is that the containers and dunnage inserts must be kept clean in order not to damage or dirty the shipped components. To wash the containers, the containers are often put through automatic washing machines which use high pressure fluids to clean the containers. The high pressure fluids often damage the dunnage inserts or remove them from the container all together. In addition, the fluids often collect in undesirable locations on or in the dunnage inserts and containers thereby creating an undesirable situation when placing new components into containers.

Other known designs have secured the dunnage inserts into the shipping container by attaching the dunnage inserts to the shipping container through the use of hook and loop fasteners or rivets. These methods of connecting the dunnage inserts to the shipping container are expensive and cannot be recycled, as the connecting methods cannot be easily removed from the shipping container. In addition, non-releasable connecting methods, such as rivets, do not allow the dunnage inserts to be removed from the shipping container, and thus, the dunnage inserts cannot be interchanged with other dunnage inserts into common shipping containers in order to receive differently shaped components.

It would be desirable to create an industrial shipping container that securely holds a component during shipping while having the ability to be used with numerous components having different configurations.

SUMMARY

The present invention relates to an industrial container apparatus for the shipment and movement of components therein. The industrial container apparatus comprises a container body, a dunnage insert, and a releasable connector. The container body has a base and at least two walls extending from the base. The dunnage insert is configured to receive and retain the components. The releasable connector removably attaches the dunnage insert to the container body in a fixed position and a detached position. The dunnage insert is retained in the container body in the fixed position. The dunnage insert is removed from the container body in the detached position.

The releasable connector may comprise one of the container body or the dunnage insert having at least one aperture. The other of the container body or the dunnage insert has at least one tab receivable by the at least one aperture to retain the dunnage insert in the fixed position and to allow the dunnage insert to be removed from the container body in the detached position. The at least one tab may have a substantially elongated planar configuration that extends from the dunnage insert. The releasable connector may comprise at least one of the at least two walls of the connector body having at least one aperture and the dunnage insert having at least one tab receivable by the at least one aperture to retain the dunnage insert in the fixed position and to allow the dunnage insert to be removed from the container body in the fixed position. The at least one aperture may be formed adjacent to the base of the container body. The at least one aperture may be formed in the base of the container body. The at least two walls of the container body may have an offset portion, wherein the at least one aperture is formed in the offset portion to receive and prevent the at least one tab of the dunnage insert from being exposed outside of the at least two walls. The at least one aperture may have a substantially elongated configuration that extends parallel to the base of the container body. The at least one aperture may have a substantially elongated configuration that extends perpendicular to the base of the container body. The releasable connector may comprise at least one flange and at least one tab formed in the dunnage insert. The at least one flange is integrally formed in the at least two walls of the container body. The at least one tab is adaptable to be retained by the at least one flange of the container body in the fixed position and to allow the dunnage insert to be removed from the container body in the detached position.

The dunnage insert may further comprise a dunnage perimeter, at least one retaining structure, and at least one connector. The dunnage perimeter has substantially the same configuration as the container body. The at least one retaining structure is adaptable to receive and secure the components. The at least one connector integrally connects the at least one retaining structure to the dunnage perimeter. The at least one retaining structure may have a bottom portion at least two side walls. The bottom portion of the retaining structure has at least one landing area for supporting the components. The side walls of the retaining structure retain and separate the components.

Variations in these and other aspects of this disclosure will be described in additional detail hereafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

FIG. 1 is an isometric view showing the industrial container assembly of the present invention;

FIG. 2 is an isometric view showing the container body without the dunnage insert of the industrial container assembly of the present invention;

FIG. 3 is an isometric view showing the dunnage insert of the industrial container assembly of the present invention;

FIG. 4 is an isometric view showing the attachment area between the container body and the dunnage insert of the industrial container assembly of the present invention;

FIG. 5 is an exploded isometric view of the container assembly including the container body and the dunnage insert of the industrial container assembly of the present invention;

FIG. 6 is a top view of the container body with apertures located in the base of the industrial container assembly of the present invention;

FIG. 7 is a side view of the container body with apertures located on the sides of the base of the industrial container assembly of the present invention; and

FIG. 8 is an isometric view of an embodiment where the dunnage insert tabs are retained by the flanges incorporated into the container body of the industrial container assembly of the present invention.

DETAILED DESCRIPTION

As seen in FIGS. 1-8, an industrial container apparatus 10 of the present invention includes a container body 12 and a removable dunnage insert 30 for receiving and securing at least one component 50 for shipping and/or transporting the components 50 without damage. The industrial container apparatus 10 may provide an attached position, wherein the dunnage insert 30 is removably retained by the container body 12, and a detached position, wherein the dunnage insert 30 is removed from the container body 12. The dunnage insert 30 includes at least one tab 38 that is configured to be releasably retained by apertures 22 provided in the container body 12. The apertures 22 in the container body 12 releasably receive each of the tabs 38 provided on the dunnage insert 30 for securing the dunnage insert 30 in the attached position.

The container body 12 is configured to retain the dunnage insert 30 for receiving and securing the components 50 therein during shipping and transport. As seen in FIG. 2, the container body 12 includes a substantially rectangular base 14 having substantially rounded corners and four upstanding vertically oriented walls 16A, 16B extending integrally upward at substantially right angles from a perimeter of the base 14. The four walls 16A, 16B include two opposing side walls 16A that are substantially parallel to one another and two opposing end walls 16B that are substantially parallel to one another and substantially perpendicular and connected to the side walls 16A. The container body 12 has an open ended top portion, but other designs are contemplated. For instance, the container body 12 may include only two walls 16A, 16B extending from the base 14, such that two sides of the container body 12 remain open. Additionally, the container body 12 may include a removable lid (not shown) to enclose the open ended top portion of the container assembly 10. The container body 12 may also vary in shape and size, depending on the desired components 50 being shipped. For instance, the container body 12 could have a substantially circular base as opposed to the substantially rectangular base 14 described therein. The height and thickness of the walls 16A, 16B may also vary depending on the application. One or more of the walls 16A, 16B may have a top edge structure 20 to assist in stacking a plurality of substantially similar container bodies 12 on top of one another in a stable condition. Similarly, a bottom surface of the base 14 may be formed with such shapes or textures that engage portions of the top edge structure 20 to allow for the stable stacking of the container bodies 12. A label area 26 may be formed in at least one of the walls 16A, 16B of the container body 12 to allow labels or other identification markings to be placed upon the container body 12. The bottom of the container body 12 can also have a pallet-type structure (not shown) with a plurality of slots or grooves to receive forks of a lift truck for lifting and transporting the industrial container apparatus 10.

As further depicted in FIG. 2, one or more of the side walls 16A of the container body 12 may include an integral offset portion 18 which is substantially centered on the side walls 16A while extending inward toward the center of the container body 12. A plurality of the apertures 22 is located in the offset portion 18 of the side walls 16A. A surface 24 of the offset portion 18 of the side walls 16A defines the apertures 22. In this way, the offset portion 18 of the walls 16 can provide further support for the container body 12 near the apertures 22 and can prevent the tabs 38 of the dunnage insert 30 from being exposed outside of the side walls 16A when engaged through the apertures 22. The apertures 22 are shown in two of the opposing side walls 16A, but it is contemplated that the apertures 22 can be formed in any or all of the walls 16A, 16B of the container body 12. The apertures 22 can extend partially or fully through the walls 16A, 16B of the container body 12.

In order to retain and secure the components 50, the dunnage insert 30 can include preformed retaining structures 32 having a certain size and shape, as seen in FIG. 3. The retaining structures 32 are designed to receive and secure the particular shape of the components 50 being shipped. The retaining structures 32 of the dunnage insert 30 may allow for the retention of a substantially cylindrical-shaped component 50, as seen in FIG. 8, although it is contemplated that the retaining structures 32 can take on a variety of shapes depending on the particular components 50 being shipped. The retaining structures 32 generally have a bottom portion 33 which may have at least one landing area for supporting the component 50 and side walls 35 to retain and separate the multiple components 50. The dunnage insert 30 may further provide connectors 34 that integrally connect the retaining structures 32 to each other such that the dunnage insert 30 is one integral piece, although it is also anticipated that the dunnage insert 30 may include a plurality of pieces. The dunnage insert 30 can include a dunnage perimeter 36, which is sized in the approximate shape as the container body 12 so as to be closely received by the container body 12.

In order to secure the dunnage insert 30 to the container body 12, a releasable connector for removably retaining the dunnage insert 30 to the container body 12 utilizes the tabs 38 of the dunnage insert 30 for attaching the dunnage insert 30 to the container body 12, as seen in FIG. 3. Each of the tabs 38 has a substantially elongated planar configuration that is comprised of a tab contact surface 42 that extends from the dunnage perimeter 36 and terminates with an end surface 40 of the tab 38. The end surface 40 of the tab 38 can be rounded to aid in the insertion and removal of the tabs 38 into and from the container body 12. The tab contact surface 42 is sized accordingly to fit within the apertures 22 in the container body 12 and may have a length sufficient to pass through the apertures 22 so that the end surface 40 engages an exterior surface of the side walls 16A of the container body 12. While shown as substantially straight and smooth, the tabs 38 can vary in length, shape, and thickness, and can include surface anomalies or structures that would result in a substantially snug fit inside the apertures 22 of the container body 12 when the dunnage insert 30 is in the attached position.

As seen in more detail in FIG. 4, there exists an attachment area between the dunnage insert 30 and the container body 12. The tabs 38 extend into and through the aperture 22 of the container body 12 when the dunnage insert 30 is in the attached position. The aperture surface 24 overlays the tab contact surface 42, wherein the contact between the aperture surface 24 and the tab contact surface 42 prevents the dunnage insert 30 from separating from the container body 12. As previously mentioned, the apertures 22 may extend through the entire thickness of the side walls 16A, but it is further contemplated that the walls 16A, 16B can have apertures (not shown) on the inside surface of the walls 16A, 16B that do not extend through the walls 16A, 16B, such as slots sized to receive the tabs 28 of the dunnage insert 30. The embodiment shown has the apertures 22 defined only in the offset portion 18 of the side walls 16A, but the apertures 22 can be located in any arrangement in the container body 12.

In the attached position, the dunnage insert 30 is retained in a fixed position through the interaction of the tabs 38 and the apertures 22, and in particular, the tab contact surface 42 and the aperture surface 24, as seen in FIGS. 1 and 4. The tab contact surface 42 restricts movement of the tabs 38 in a direction substantially perpendicular to the depth of the aperture 22. Thus, as shown, the tab contact surface 42 restricts the tabs 38 from moving in a vertical and horizontal direction. The dimensions of the dunnage insert 30 and the dunnage perimeter 36 can prevent movement in an aperture depth direction by fitting closely within the walls 16A, 16B of the container body 12. It is also contemplated that the tabs 38 can be sized accordingly to create a substantially snug fit within the aperture 22, such that the tab 38 is restricted through frictional forces in a direction parallel with the aperture depth direction. The tabs 38 may also have clips or other attachment means to lock the tabs 38 into an attached position within the apertures 22.

To insert the dunnage insert 30 into the attached position, the dunnage insert 30 is moved toward the container body 12 in the direction indicated by arrow A, as shown in FIG. 5. The dunnage insert 30 can have a degree of flexibility and elasticity such that the tabs 38 may be forced down along the inside of the walls 16A, 16B until reaching the apertures 22 of the container body 12, at which point the tabs 38 spring into the apertures 22. Alternatively, the dunnage insert 30 can be inserted into the container body 12 at an angle, such that the tabs 38 on one side of the dunnage insert 30 are first placed within the apertures 22, and the tabs 38 on the opposite side of the dunnage insert 30 are then forced into the apertures 22 on the opposing side wall 16A.

To remove the dunnage insert 30 from the container body 12 into the detached position, a force may be applied to the dunnage insert 30 in a direction away from the container body 12 (opposite the direction of arrow A in FIG. 5), wherein the removal of the dunnage insert 30 from the container body 12 may be aided by applying a force to the tabs 38 in a direction towards the interior of the container body 12. The dunnage insert 30 can slightly deform, thereby allowing the tabs 38 to move in a direction towards the center of the dunnage insert 30 and allowing the tabs 38 to clear the aperture surface 24 of the apertures 22.

In an alternative embodiment of the container body 12, the apertures 22 may be formed in the base 14, as shown in FIG. 6. In this embodiment, the dunnage insert 30 has the tabs 38 located on a bottom surface of the dunnage insert 30 wherein the tabs 38 are sized to fit in the apertures 22. The tabs 38 extend from an area on the bottom surface of the dunnage insert 30 in at least a partial vertical direction away from the bottom surface of the dunnage insert 30 such that the tabs 38 can engage the apertures 22 in the attached position.

In yet another embodiment, the apertures 22 are oriented vertically in a central area of the offset portion 18 of the side walls 16A of the container body 12, as seen in FIG. 7. The dunnage insert 30 correspondingly provides the tabs 38 in a higher location than the embodiment shown in FIG. 3, which would be configured to engage the apertures 22 in the location shown. The tabs 38 in this case may project vertically from the walls of the retaining structures 32 of the dunnage insert 30, for example.

In even yet another embodiment of the invention, the releasable connector may also provide the tabs 38′ which are retained by flanges 23 that are integrally formed in the walls 16A, 16B of the container body 12, as seen in FIG. 8. The tabs 38′ are formed in the dunnage insert 30 at the dunnage perimeter 36, extending in a direction substantially parallel to the walls 16A, 16B of the container body 12 when the dunnage insert 30 is located in the container body 12. The tabs 38′ may also be supported by the connectors 34 of the dunnage insert 30. The flanges 23 are configured as angled surfaces protruding towards the interior of the container body 12 relative to the walls 16A, 16B. Other designs of the flanges 23 are contemplated, such as any surface that extends towards the interior of the container body 12 capable of retaining the tabs 38′ in the attached position. Insertion and removal of the dunnage insert 30 may be accomplished by using a similar method of applying a force in a downward or upward direction as previously described, and the tabs 38′ can slightly deform to allow the tabs 38′ to move below the flanges 23. The flanges 23 can be substantially rigid or can be substantially flexible to aid in the insertion or removal of the tabs 38′ from the container body 12 between the attached position and the detached position.

The dunnage insert 30 of the embodiments shown have fixed, integrally formed tabs 38, 38′, but it is contemplated that the tabs 38, 38′ may extend and retract, or otherwise move to aid in the attachment or removal of the dunnage insert 30 into and from the container body 12. It also anticipated that tabs 38, 38′ and the apertures 22 could be reversed, such that the container body 12 provides the tabs 38, 38′ and the dunnage insert 30 provides the apertures 22.

Both the container body 12 and the dunnage insert 30 are constructed from a polymeric material manufactured by an injection molding process. This provides for lightweight, durable construction of both the container body 12 and the dunnage insert 30. It is also contemplated that the container body 12 and the dunnage insert 30 can be produced using several additional materials and processes. Thus, the container body 12 and/or the dunnage insert 30 can be produced using a variety of polymers or metals through such manufacturing processes as die cut assemblies, thermoforming, injection molding, extrusion, and other known machining processes to create containers or dunnage suitable for the shipment or movement of desired components. As previously noted, the container body 12 has such a durable construction that the container body 12 can be used to contain and transport materials and components in bulk when the dunnage insert 30 has been removed from the container body 12. In addition, the container body 12 and the dunnage insert 30 may also be utilized to secure the component 50 for various types of material processing, such as manufacturing and assembly processing.

While the invention has been described in connection with certain embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. 

What is claimed is:
 1. An industrial container apparatus for the shipment and movement of components therein, the industrial container apparatus comprising: a container body having a base and at least two walls extending from the base; a dunnage insert configured to receive and retain the components; and a releasable connector for removably attaching the dunnage insert to the container body in a fixed position, wherein the dunnage insert is fixedly retained in the container body, and a detached position, wherein the dunnage insert is removed from the container body.
 2. The industrial container apparatus of claim 1, wherein the releasable connector further comprises: one of the container body or the dunnage insert having at least one aperture; and the other of the container body or the dunnage insert having at least one tab receivable by the at least one aperture to retain the dunnage insert in the fixed position and to allow the dunnage insert to be removed from the container body in the detached position.
 3. The industrial container apparatus of claim 2, further comprising: the at least one tab having a substantially elongated planar configuration.
 4. The industrial container apparatus of claim 1, wherein the releasable connector further comprises: at least one of the at least two walls of the connector body having at least one aperture; and the dunnage insert having at least one tab receivable by the at least one aperture to retain the dunnage insert in the fixed position and to allow the dunnage insert to be removed from the container body in the detached position.
 5. The industrial container apparatus of claim 4, further comprising: the at least one aperture being formed adjacent to the base of the container body.
 6. The industrial container apparatus of claim 4, further comprising: the at least one aperture being formed in the base of the container body.
 7. The industrial container apparatus of claim 4, further comprising: the at least two walls of the container body having an offset portion, wherein the at least one aperture is formed in the offset portion to receive and prevent the at least one tab of the dunnage insert from being exposed outside of the at least two walls.
 8. The industrial container apparatus of claim 4, further comprising: the at least one aperture having a substantially elongated configuration that extends parallel to the base of the container body.
 9. The industrial container apparatus of claim 4, further comprising: the at least one aperture having a substantially elongated configuration that extends perpendicular to the base of the container body.
 10. The industrial container apparatus of claim 1, wherein the releasable connector further comprises: at least one flange integrally formed in at least one of the at least two walls of the container body; and at least one tab formed in the dunnage insert, the at least one tab adaptable for releasably engaging the at least one flange of the container body in the fixed position and allowing the dunnage insert to be removed from the container body in the detached position.
 11. The industrial container apparatus of claim 1, wherein the dunnage insert further comprises: a dunnage perimeter having substantially the same configuration as the container body; at least one retaining structure adaptable to receive and secure the components; and at least one connector that integrally connects the at least one retaining structure to the dunnage perimeter.
 12. The industrial container apparatus of claim 10, wherein the at least one retaining structure further comprises: a bottom portion having at least one landing area for supporting the components; and at least two side walls to retain and separate the components.
 13. An industrial container apparatus for the shipment and movement of components therein, the industrial container apparatus comprising: a container body having a base, at least two walls extending from the base, and at least one aperture; and a dunnage insert configured to receive and retain the components, the dunnage insert having a dunnage perimeter having substantially the same configuration as the container body, at least one retaining structure being adaptable to receive and secure the components, at least one connector integrally connecting the at least one retaining structure to the dunnage perimeter, and at least one tab being adaptable to be received by the at least one aperture in the container body and to removably attach the dunnage insert to the container body in a fixed position, wherein the dunnage insert is fixedly retained in the container body, and a detached position, wherein the dunnage insert is removed from the container body.
 14. The industrial container apparatus of claim 13, further comprising: the at least two walls of the container body having an offset portion, wherein the at least one aperture is formed in the offset portion to receive and prevent the at least one tab of the dunnage insert from being exposed outside of the at least two walls of the container body.
 15. The industrial container apparatus of claim 14, further comprising: the at least one tab of the dunnage insert having a substantially elongated planar configuration extending from the dunnage perimeter of the dunnage insert.
 16. The industrial container apparatus of claim 15, further comprising: the at least one aperture being formed adjacent to the base of the container body.
 17. The industrial container apparatus of claim 16, wherein the at least one retaining structure further comprises: a bottom portion having at least one landing area for supporting the components; and at least two side walls to retain and separate the components.
 18. An industrial container apparatus for the shipment and movement of components therein, the container comprising: a container body having a base, a first set of two parallel side walls extending from the base, a second set of two parallel side walls extending from the base, wherein the first set of two parallel side walls are perpendicular to the second set of two parallel side walls, and a plurality of apertures formed in the first set of two parallel side walls; and a dunnage insert configured to receive and retain the components, the dunnage insert having a dunnage perimeter having substantially the same configuration as the container body, at least one retaining structure being adaptable to receive and secure the components, at least one connector integrally connecting the at least one retaining structure to the dunnage perimeter, and at least one tab being adaptable to be received by the at least one aperture in the container body and to removably attach the dunnage insert to the container body in a fixed position, wherein the dunnage insert is fixedly retained in the container body, and a detached position, wherein the dunnage insert is removed from the container body.
 19. The industrial container apparatus of claim 18, further comprising: the first set of two parallel side walls having an offset portion, wherein the plurality of apertures are formed in the offset portion to receive and prevent the plurality of tabs of the dunnage insert from being exposed outside of the first set of two parallel side walls.
 20. The industrial container apparatus of claim 19, wherein the plurality of tabs of the dunnage insert have a substantially elongated planar configuration extending from the dunnage perimeter of the dunnage insert, and the plurality of apertures in the first set of two parallel side walls is adjacent to the base of the container body. 